Diaper having multi-layer and single layer fabric sections with similar warp end count



Apnl 25, 1967 N. L. SELTZER 3,315,675

DIAPER HAVING MULTI-LAYER AND SINGLE LAYER FABRIC SECTIONS WITH SIMILAR WARP END COUNT Filed March 10, 1964 WAQPMS INVENTOR. NORMAN L. SELTZER ATTORNEY5 United States Patent Massachusetts Filed Mar. 10, 1964, Ser. No. 350,845 7 Claims. (Cl. 128-284) The present invention relates to diapers and more particularly to those diapers of the prefold type which are usually folded to provide superposed fabric layers and are then stitched together in this folded condition.

Prefold diapers are primarily preferred by the com mercial laundry or diaper service trade and there are many types of conventional prefold diapers which are usually formed of gauze diaper fabric woven in juxtaposed sections which may be either single ply or multiply. The diaper fabric is cut transversely to the desired size and is then folded to form a generally rectangular pad which is secured in the folded condition by stitching extending longitudinally of the pad at spaced apart points and usually across the ends thereof to prevent raveling.

While these gauze diapers have enjoyed considerable commercial success, it has been determined that the absorbency and wearability of the diapers may be greatly enhanced by a novel arrangement of the yarns in the various areas of the fabric with the resulting fabric having a density above the density of conventional gauze diapers but wherein the yarn sizes, total yarn count and weight of the resulting diaper are within the corresponding ranges of conventional gauze diaper fabric.

Gauze diaper fabric for conventional prefold diapers is usuall of plain weave construction and has a warp end count within the range of about 3248 and a filling pick count of about 32-52 and yarn numbers of about 20s-30s in the warp and about 25s40s in the filling. Conventional gauze diapers usually have a standard width of about 21 inches and a standard length of about 40 inches prior to being folded. Therefore, these diapers .have a total warp end count within the range of about 2560 to 3920 and a total filling pick count within the range of about 1240 to 1550. Such conventional gauze diapers accordingly range in weight from about 54 to 69 grams, which range of weights are necessary to give the required absorbency characteristics in such diapers while making the diapers economically feasible.

As is well known, in prefold diapers, the greatest wear occurs on the outer surface of the central portion of the diaper and along the edge portions of the diaper. Also, the greatest absorptive capacity of a diaper should be in the central portion where it is needed most.

conventionally, gauze prefold diapers are subject to considerable shrinkage upon repeated laundering. This shrinkage results in considerable unsightly wrinkling of the diapers which in turn shortens the effective life of the diapers due to increased wear at the crests of the wrinkles. Also, this shrinkage results in problems of proper fit on a growing wearer since the diapers become progressively smaller while the wearer is becoming progressively larger.

It is therefore an object of the present invention to provide a novel prefold diaper having an over-all weight within the range of weights of conventional gauze diapers and wherein the yarn sizes, total warp end count and total filling pick count are within the range of conventional gauze diapers, and wherein increased wear-resistance, reduced shrinkage and thus reduced wrinkling resulting therefrom, and hence greater wearability, and greater absorbency in at least the central area of the diaper are provided than are provided by conventional gauze prefold diapers.

A more specific object of the present invention is to provide a novel prefold diaper having multi-layer and single layer fabric sections and wherein these layers are formed of fabric of greater density than conventional gauze diaper fabric while maintaining the total warp end count, total filling pick count, yarn sizes and weight within the range of conventional gauze diapers.

Some of the objects of the invention having been stated, other objects will appear as the description proceeds, when taken in connection with the accompanying drawings, in which FIGURE 1 is a perspective view of a diaper embodying the features of the present invention;

FIGURE 2 is an enlarged fragmentary sectional perspective view taken substantially along line 2-2 in FIGURE 1;

FIGURE 3 is a plan view of the diaper shown in FIG- URE 1 in unfolded condition;

FIGURE 4 is a schematic view showing, in draft form, one repeat of the preferred float-type weave of the multilayer portions of the instant diaper, the warp yarns runnlng vertically and the filling yarns running horizontally, and the Xs indicating where the warp yarns pass over the filling yarns; and

FIGURE 5 is a schematic view similar to FIGURE 4 showlng the preferred weave in the single layer portions of the diaper shown in FIGURES 1-3.

Referring now to the drawings and more particularly to FIGURE 1, there is shown a diaper generally indicated at 10 which includes a central panel 11 defining the central area of the diaper, side panels 12 and 13 on opposite sides of the central panel 11, respectively, and side edge portions 14 and 15 joined to the side panels 12 and 13, respectively.

Central panel 11 is formed of preferably three superposed multi-layer fabric sections 20', 21 and 22. These fabric sections each comp-rise two'layers of fabric 20a, 20b, 21a, 21b and 22a, 221), respectively. Side panels 12 and 13 are formed of upper and lower single layer fabric sections 23, 24 and 25, 26, respectively. Sections 23 and 25 are woven integrally with opposite sides of central panel section 20; side panel section 24 is woven integrally with one side of central panel sections 22; and side panel section 26 is woven integrally with one side of central panel section 21. The other sides of central panel sectionls 21 and 22 are defined by selvages 30, 31, respectrve y.

Side edge portions 1-4 and 15 of diaper 10' each comprise two layers of fabric 32, 33 and 34, 35, respectively. Side edge portions 14 and 15 are formed into U-shape when the diaper 10 is folded intermediate the side edges thereof. The diaper 10 is preferably folded to superpose sections 20, 21 and 22 of central panel 11 and is secured in this folded condition by spaced lines of stitching 40, 41 extending lengthwise of central panel 11 between the ends thereof. Also, suitable over-edge sitching 42, 43 is preferably provided at opposite ends of diaper 10 to prevent raveling thereof.

As will be seen in FIGURE 3, the panels of diaper 10 preferably extend in a warpwise direction between the ends of the diaper when folded. The blank from which diaper 10 is formed is severed from a web of woven fabric and is preferably about 40 inches in a fillingwise direction and about 21 inches in a warpwise direction. It is contemplated, however, that this blank may be formed in any desired size.

The present diaper has a total warp end count and filling pick count within the aforesaid total warp end count range of 2560 to 3920 and total filling-pick count range of 1240 to 1550 of conventional gauze diapers. Both the warp and filling yarn sizes are within the aforesaid yarn size ranges of s to 30s in the warp and s to 40s in the filling for conventional gauze diaper fabric and more particularly, s warp and filling yarns are preferred in the instant diaper. However, the density in the fabric layers of the instant diaper is greater than the density in the layers of conventional gauze diaper fabric to provide the above-mentioned greater wearability and absorbency characteristics. In this respect, each of the fabric layers of all of the sections of diaper ltl has a preferred warp end count of about 62 to 68 ends per inch which is materially above the warp end count range of 32448 of conventional gauze diaper fabric. Also, each of the fabric layers of central panel sections 20, 21 and 22 and side edge portions 14 and 15. has a preferred filling pick count within the range of about 28 to 36. Further, each of the layers of the side panel sections has a preferred filling pick count within the range of about 56 to 72 which is materially above the filling pick count range of 32 to 52 of conventional gauze diaper fabric.

It is noted that this preferred diaper construction provides the same warp end count throughout the various layers of the diaper which results in twice as many warp yarns per inch in each section of the central panel than in each section of the side panels. This novel arrangement of yarns provides greatly increased absorbency in the central panel as well as increased strength and wear-resistancetherein. Further, this arangement permits the diaper to be not only folded in the manner shown and described, but also to be folded in a reverse manner to that shown to use the opposite face of the woven fabric.

The fabric layers of diaper 10 are woven in a floattype weave to provide increased softness of the diaper. As user herein, float-type weave shall mean any weave wherein the warp yarns pass over or under more than one filling yarn between interlacings thereof. In at least the layers of the central panel, it is preferred that a weave be utilized which will provide a predominance of warp yarns, which conventionally are formed with a higher twist, floated over filling yarns on the outer surface thereof to provide increased wearability. In accordance with the present invention, the float-type weave used in the central panel sections should provide the maximum number of interlacings for a given number of yarns to obtain the desired stability and wearability while still providing the desired softness. This maximum number of interlacings provides greater lengths of yarns and therefore greater weight of yarn in the central panel which results in increased absorbency by increasing the moisture retention ability thereof and also results in increased absorbency by increasing the moisture capacity thereof due to the float weave arrangement. The single layer side panel sections preferably are formed of a weave providing less yarn interlacings for a given number of yarns than would be provided therein by the weave of the central panel layers and thereby providing increased softness therein and better pinability due to easier passage of pins therethrough, while also providing resistance to' fray, shrinkage and wrinkling.

Examples of float-type weaves which may be used in the multi-layer sections and single layer sections are shown respectively in FIGURES 4 and 5. The weave design shown in FIGURE 4 comprises one repeat of a 2/1 left-hand warp float twill which is preferred in the fabric forming the layers of central panel sections 20, 21, 22 and side edge portions 14 and 15. The numbers 1, 2, 3, 4, 5 and 6 reading from the bottom up along the lefthand side of FIGURE 4 correspond to the order in which the picks or filling yarns are inserted and the numbers 1, 2, 3, 4, 5 and 6 along the bottom of FIGURE 4 correspond to the warp yarns which form the shed in which the picks are inserted. It is noted that warp yarns 1, 3 and 5 are used to form one layer of the multi-layer sections and warp yarns 2, 4 and 6 are used to form the other layer thereof. Also, the picks progress from one -layer to the'other informing the fabric and, therefore,

Picks 3 and 5 in each repeat are interwoven with warp yarns 1, 3 and 5 to form said one layer and picks 2, 4 and 6 are interwoven with warp yarns 2, 4 and 6 to form the other.

The weave design shown in FIGURE 5 comprises one repeat of a 2/2 regular twill (left-hand), which is preferred for the single layer sections of diaper 10. It is therefore noted that this weave in the single layer sections has one more warp yarn and one more filling yarn per weave repeat than the weave in the multi-layer sections and thus these single layer fabric sections have less yarn interlacings for a given number of yarns than the multi-layer fabric sections for the reasons stated above.

It is noted that not only does a diaper constructed in accordance with the present invention have increased wear-resistance and absorbency in the areas thereof where the same are needed most, but it has been discovered that such a diaper also will shrink considerably less than conventional gauze prefold diapers upon repeated laundering. Therefore, undesirable wrinkling is reduced which materially increases the effective life of the diaper and which also provides a diaper of more pleasing appearance. Also, due to this reduced shrinkage, a diaper is provided which will fit a growing wearer better and for a longer period of time than conventional gauze prefold diapers.

It will therefore be apparent that a novel prefold diaper is provided having greater wearability and absorbency characteristics where needed most as compared to conventional gauze prefold diapers while still having a weight within the range of weights of conventional gauze diapers and a total warp end count, a total filling pick count and yarn sizes within the corresponding ranges of conventional gauze diapers.

In the drawings and specification there has been set forth a preferred embodiment of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.

I claim:

1. In a prefolded multiple layer woven diaper having a total warp end count, total filling pick count, yarn sizes and over-all weight within the corresponding ranges of conventional gauze diapers, said diaper being characterized by the layers thereof being formed of fabric of greater density than conventional gauze diaper fabric and being further characterized by having substantially greater wearability and greater absorbency in at least the central area of the diaper than conventional gauze diapers; said diaper comprising a plurality of juxtaposed, warpwise extending panels including a central panel defining the central area of the diaper and comprising a plurality of superposed multi-layer fabric sections, and side panels connected to opposite sides of said central panel and comprising upper and lower single layer fabric sections, the filling yarns in the respective multi-layer central panel sections extending through the single layer side panel sections, the warp end count in each of central panel sections and of said side panel sections being substantially the same and being materially above the warp end count range of 32-48 of conventional gauze diaper fabric, the filling pick count in each of said single layer fabric sections being materially above the filling pick count range of 32-52 of conventional gauze diaper fabric, the filling pick count in at least the outer layers of the central panel being no less than the quotient obtained by dividing the filling pick count of a side panel section by the number of layers in a central panel section, and all of said fabric sections being woven in a floattype weave to provide increased softness of the fabric sections.

2. A diaper according to claim 1 including rrtulti-layer U-shaped fabric sections joined to said upper and lower sections of said side panels and defining side edge portions of the diaper, and the layers of said U-shaped fabric the layers of the.

sections having substantially the same warp end count as the layers of said central panel sections.

3. A diaper according to claim 1 wherein said central panel sections each has the same number of fabric layers therein and wherein the filling pick count in each layer of the central panel sections is equal to the quotient obtained by dividing the filling pick count in a side panel section by the number of layers in a central panel section.

4. In a prefolded multiple layer Woven diaper having a total warp end count, total filling pick count, yarn sizes and over-all weight within the corresponding ranges of conventional gauze diapers, said diaper being characterized by the layers thereof being formed of fabric of greater density than conventional gauze diaper fabric and being further characterized by having substantially greater wearability greater absorbency in at least the central area of the diaper than conventional gauze diapers; said diaper comprising a plurality of juxtaposed, warpwise extending panels including a central panel defining the central area of the diaper and comprising a plurality of superposed two-layer fabric sections, side panels connected to opposite sides of said central panel and comprising upper and lower single layer fabric sections, and two-layer U-shaped fabric sections joined to said upper and lower sections of said side panels and defining side edge portions of the diaper, the filling yarns in the twolayer central panel sections and U-shaped fabric sections extending through the single layer side panel sections, the warp end count in all layers of the diaper being substantially the same and being materially above the Warp end count range of 32-48 of conventional gauze diaper fabric, the filling pick count in each of said single layer fabric sections being materially above the filling pick count range of 3252 of conventional gauze diaper fabric, the filling pick count in the layers of the central panel sections and U-shaped fabric sections being the same and being equal to one-half the filling pick count of the side panel sections, and all of said sections being woven in a float-type weave to provide increased softness of the diaper.

5. A diaper according to claim 4 wherein said central panel comprises three superposed two-layer fabric sections, the warp end count in all layers of the diaper is about 62 to 68 ends per inch, and the filling pick count in the layers of said side panels is between about 56 and 72 picks per inch.

6. In a prefolded elongate multiple layer woven diaper having a total warp end count, total filling pick count, yarn sizes and over-all Weight within the correspending ranges of conventional gauze diapers, said diaper being characterized by the layers thereof being formed of fabric of greater density than conventional gauze diaper fabric and being further characterized by having 5 substantially greater wearability and greater absorbency in at least the central area of the diaper than conventional gauze diapers; said diaper comprising a plurality of juxtaposed, warp-wise extending panels including a central panel defining the central area of the diaper and comprising three superposed two-layer fabric sections, side panels connected to opposite sides of said central panel and comprising upper and lower single layer fabric sections, and two-layer U-shaped fabric sections joined to said upper and lower sections of said side panels and defining side edge portions of the diaper, the filling yarns in the two-layer central panel sections and U-shaped fabric sections extending through the single layer side panel sections, the warp end count in all layers of the diaper being about 62 to 68 ends per inch, the filling pick count in each of said single layer side panel sections being about 72 picks per inch, the filling pick count in the layers of the central panel sections and U-shaped fabric sections being about 36 picks per inch, and all of said fabric sections being woven in a float-type weave to provide increased softness of the diaper.

7. A diaper according to claim 6 wherein said panels extend the full length of the diaper, wherein the floattype weave of the single layer side panel sections, which have the greatest density, presents less yarn interlacings per given number of yarns than the float-type weave of the multi-layer sections, and including stitching along opposite sides of said central panel and across the ends of all of said panels to secure the diaper in folded con- 35 dition ready for use.

References (:ited by the Examiner UNITED STATES PATENTS OTHER REFERENCES Staple Cotton Fabrics, 1942, page 133 Hoye, John:

relied on.

ROBERT E. MORGAN, Acting Primary Examiner. L, W. TRAPP, Assistant Examiner. 

1. IN A PREFOLDED MULTIPLE LAYER WOVEN DIAPER HAVING A TOTAL WARP END COUNT, TOTAL FILLING PICK COUNT, YARN SIZES AND OVER-ALL WEIGHT WITHIN THE CORRESPONDING RANGES OF CONVENTIONAL GAUZE DIAPERS, SAID DIAPER BEING CHARACTERIZED BY THE LAYERS THEREOF BEING FORMED OF FABRIC OF GREATER DENSITY THEN CONVENTIONAL GAUZE DIAPER FABRIC AND BEING FURTHER CHARACTERIZED BY HAVING SUBSTANTIALLY GREATER WEARABILITY AND GREATER ABSORBENCY IN AT LEAST THE CENTRAL AREA OF THE DIAPER THAN CONVENTIONAL GAUZE DIAPERS; SAID DIAPER COMPRISING A PLURALITY OF JUXTAPOSED, WARPWISE EXTENDING PANELS INCLUDING A CENTRAL PANEL DEFINING THE CENTRAL AREA OF THE DIAPER AND COMPRISING A PLURALITY OF SUPERPOSED MULTI-LAYER FABRIC SECTIONS, AND SIDE PANELS CONNECTED TO OPPOSITE SIDES OF SAID CENTRAL PANEL AND COMPRISING UPPER AND LOWER SINGLE LAYER FABRIC SECTIONS, THE FILLING YARNS IN THE RESPECTIVE MULTI-LAYER CENTRAL PANEL SECTIONS EXTENDING THROUGH THE SINGLE LAYER SIDE PANEL SECTIONS, THE WARP END COUNT IN EACH OF THE LAYERS OF THE CENTRAL PANEL SECTIONS AND OF SAID SIDE PANEL SECTIONS BEING SUBSTANTIALLY THE SAME AND BEING MATERIALLY ABOVE THE WARP END COUNT RANGE OF 32-48 OF CONVENTIONAL GAUZE DIAPER FABRIC, THE FILLING PICK COUNT IN EACH OF SAID SINGLE LAYER FABRIC SECTIONS BEING MATERIALLY ABOVE THE FILLING PICK COUNT RANGE OF 32-52 OF CONVENTIONAL GAUZE DIAPER FABRIC, THE FILLING PICK COUNT IN AT LEAST THE OUTER LAYERS OF THE CENTRAL PANEL BEING NO LESS THAN THE QUOTIENT OBTAINED BY DIVIDING THE FILLING PICK COUNT OF A SIDE PANEL SECTION BY THE NUMBER OF LAYERS IN A CENTRAL PANEL SECTION, AND ALL OF SAID FABRIC SECTIONS BEING WOVEN IN A FLOATTYPE WEAVE TO PROVIDE INCREASED SOFTNESS OF THE FABRIC SECTIONS. 